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Slipstream pilot plant demonstration of an amine-based post-combustion capture technology for CO2capture from coal-fired power plant flue gas
DOE funding award DE-FE0007453
2015 NETL CO2 Capture Technology MeetingKrish R. Krishnamurthy, Linde LLCJune 24, 2014Pittsburgh, PA
Linde, a fully integrated gases and engineering company with a long experience in the field of CO2 handling
Experience in design and erection of different wash processes for CO2
removal
• Linde-Rectisol®
• BASF OASE® technology
• Benfield
Long experience in operation of CO2 plants, transport and distribution
• OCAP pipeline (Netherlands)
• Onsite business
• Bulk supply
CO2 Capture and injection
LNG plant for Statoil in Snøhvit/Norway with CO2
capture from natural gas using OASE® purple and CO2 re-injection off-shore
CO2 Wash Units
Removal of impurities like Hydrocarbons, Heavy metals, O2, H2O for food grade CO2
CO2 Food Grade Plants CO2 Transport and distribution
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Project Budget : DOE funding and cost share (Amended Aug 2014)
Source
Budget Period 1
Dec 2011 – Feb 2013
Design & Engineer
Budget Period 2
Mar 2013 – Aug 2014
Procure & Build
Budget Period 3
Sep 2014 – Aug 2016
Operate & Test
Total
DOE Funding $2,670,173 $11,188,501 $2,360,173 $16,218,847
Cost Share $667,543 $4,335,102 $1,472,506 $6,475,151
Total Project $3,337,716 $15,523,602 $3,832,679 $22,673,998
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March 2015 Budget Actual
Total $19.33m $19.48m
DOE $14.23m $14.33m
Cost share $ 5.10m $ 5.15m
Cost share commitments:
Linde: $5,884,411
BASF: $ 493,360
EPRI: $ 97,379
Project Participants and Role
Partner/Organization
Lead contact(s) Key Role(s)
DOE-NETL Andrew P. Jones, Project Manager
-Funding & Sponsorship
Linde LLC Krish KrishnamurthyStevan JovanovicDevin Bostick
-Prime contract-Overall program management-Operations and testing
BASF Sean Rigby (BASF Corp)Gerald Vorberg (BASF SE)
-OASE® blue technology owner -Basic design-Solvent supply and analysis
EPRI Richard Rhudy -Techno-economics review-Independent validation of test analysis and results
Southern Co./NCCC
Frank MortonJustin Anthony
-NCCC Host site (Wilsonville, AL)-Infrastructure and utilities for pilot plant build and operations
Linde Engineering, Dresden
Torsten StoffregenDirk BauersfeldAnnett Kutzschbach
-Basic engineering-Support for commissioning-Operations and testing
Linde Eng. –North America
Luis VillalobosDrew Amis; Edgar Perez
-Detailed engineering-Procurement and installation
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Overall Objective
— Demonstrate Linde-BASF post combustion capture technology by incorporating BASF’s amine-based solvent process in a 1 MWe slipstream pilot plant and achieving at least 90% capture from a coal-derived flue gas while demonstrating significant progress toward achievement of DOE target of less than 35% increase in levelized cost of electricity (LCOE)
Specific Objectives
— Complete a techno-economic assessment of a 550 MWe power plant incorporating the Linde-BASF post-combustion CO2 capture technology to illustrate the benefits
— Design, build and operate the 1MWe pilot plant at a coal-fired power plant host site providing the flue gas as a slipstream
— Implement parametric tests to demonstrate the achievement of target performance using data analysis
— Implement long duration tests to demonstrate solvent stability and obtain critical data for scale-up and commercial application
Project Objectives
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BASF OASE® blue Technology DevelopmentAdopted and optimized for PCC applications
Equilibria
Kinetics
Stability
Lab scale Mini plant Pilot: 0.45MWe Pilot: 1-1.5 MWe
— Ludwigshafen, Germany
— Advanced solvent screening, development, optimization
— Ludwigshafen, Germany— Solvent performance
verification
— 2009, Niederaussem— Process optimization,
materials testing
— 2014, Wilsonville, AL— Design improvements,
emissions confirmation
Linde Engineering Dresden GmbH Source: Kyoto GHGT11 7
Niederaussem Pilot Plant: Operations and test results
Note: Specific energy above is intrinsic and does not include process or heat integration
Linde-BASF novel amine-based PCC technology features: NCCC 1 MWe pilot
Absorber
Treated flue gas
CO2
Reboiler
Desorber
Condenser
Make-up water
Solvent Tank
InterstageCooler
Steam
Advanced emission
control system
Gravity Flow
Interstage Cooler
Optimized Blower
Concept
Optimized Energy
Consumption
High capacity
structured packing
Higher Des. Pres.
Unique reboier
designDOE-NETL funding: DE-FE0007453
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Linde-BASF PCC Plant Design for 550 MWe PC Power Plant
Single train PCC design for~ 13,000 TPD CO2 capture
40-50% reduced plot areato 180m x 120 m
Key Budget Period 1 (Design & Engineer) Project Milestones Successfully completed
BP1 (Dec. 1, 2011 – Feb. 28, 2013)
— Submit project management plan (03/09/2012) √
— Conduct kick-off meeting with DOE-NETL (11/15/2011) √
— Complete initial techno-economic analysis on a 550 MWe power plant (05/04/2012) √
— Complete basic design and engineering of a 1 MWe pilot plant to be tested at NCCC (06/20/2012) √
— Execute host site agreement (10/31/2012) – completed 01/09/2013 √
— Complete initial EH&S assessment (10/31/2012) – Completed 12/14/2012 √
— Complete detailed pilot plant engineering and cost analyis for the 1 MWe pilot plant to be tested at NCCC (01/31/2013) - Completed 02/15/2013 √
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Key Budget Period 2 (Procure & Build) Project Milestones Successfully Completed
BP2 (Mar. 1, 2013 – Aug. 31, 2014)
— Complete purchase orders and fabrication contracts for the 1 MWe pilot plant (06/30/2013) √
— Complete shop fabrication of equipment and modules and associated engineering checks (12/15/2013) – Completed 12/20/2013√
— Complete site preparation and foundation installations at NCCC to receive pilot plant (11/15/2013) – Completed 1/3/2014 √
— Complete installation of the 1 MWe pilot plant at NCCC (02/28/2014) – Completed 3/28/2014√
— Mechanical completion of 1 MWe pilot plant at NCCC (05/28/2014) – Completed 7/18/2014√
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BP3 Project Schedule (Continuous availability of site and utilities)
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Mechanical completion and commissioning
● Mechanical completion of the 1 MWe pilotplant achieved : July, 2014
● Pre-start up safety review and comprehensivesystem installation checks against P&ID and design intent performed to identify issues to address prior to start up
● Machine start-up and water recirculation testswere performed in August 2014 to establish functionality and operability of system components.
Linde-BASF 1 MWe pilot plant at the NCCC
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Pilot plant start-up and initial operations
● OASE® blue solvent delivery and loading intothe NCCC pure solution storage tanks completed in December 2014. Initial solvent loading into the system performed on January 10, 2015
● Stable operations achieved within one week
● Start-up & initial operations phase goals:
–Tune control loops and establish continuousand steady operation
–Calibrate instruments/analyzers and checkout mass and energy balance closures
–Validate functionality of the uniquefeatures in pilot plant
– Demonstrate initial performance andcompare against targets
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Pilot plant operations philosophy and run time
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─ 24 x 7 operations with 2 x 10 hour shift coverage
─ Solvent recirculation continued through entire duration (mostly with steam whenever available) except for minor disruptions.
─ System run with flue gas for specific test campaigns
Time/Date Interval Hours Days
Flue Gas01/16/15 to 06/08/15 1320.2 55.0
Steam01/16/15 to 06/08/15 1985.0 82.7
Solvent Circulation
01/16/15 to 06/08/15 2193.4 91.4
Pilot plant operations and CO2 capture
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87% average CO2 capture
Flue gas flow rate to the pilot plant is typically very steady
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Flue gas composition (11.5% CO2; 7.6% O2) typically steady but showed variations from time to time ( +0.6% )
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Pilot plant set up and operations: Overall mass balance closures were excellent
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Overall Mass Balance (dry basis)
Time/Date Interval Average Mass Flow In (lb/hr) Average Mass Flow Out (lb/hr) % Difference03/15/15 21:10:00 to 03/16/15 11:30:00 10180.02 10234.55 0.53%
CO2 Mass Balance
Time/Date IntervalAverage CO2 Mass Flow In
(lb/hr)Average CO2 Mass Flow Out
(lb/hr) % Difference03/15/15 21:10:00 to 03/16/15 11:30:00 1729.01 1716.15 0.75%
CO2 Production Mass Flowrate vs. CO2 Content Solvent Analysis
Time/Date Interval
CO2 Product (lb/hr)
(calc. from solvent analysis)CO2 Product (lb/hr)
(measured) % Difference03/13/15 06:00:00 to 03/13/15 07:30:00 2348.66 2332.53 0.69%
Water balance has an effect on the overall mass and CO2 balance closures
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Overall Mass Balance (dry basis)
Time/Date Interval Average Mass Flow In (lb/hr) Average Mass Flow Out (lb/hr) % Difference
05/30/15 00:00:00 to 05/30/15 02:00:00 14802.36 14409.53 2.65
CO2 Mass Balance
Time/Date IntervalAverage CO2 Mass Flow In
(lb/hr)Average CO2 Mass Flow Out
(lb/hr) % Difference
05/30/15 00:00:00 to 05/30/15 02:00:00 2481.01 2453.03 1.13
CO2 Production Mass Flowrate vs. CO2 Content Solvent Analysis
Time/Date Interval
CO2 Product CO2 Product (lb/hr)
% Difference(lb/hr) (measured)
(calc. from solvent analysis)
05/30/15 00:00:00 to 05/30/15 02:00:00 2369.06 2236.91 5.58
Specific energy consumption vs Solvent circulation rate (comparison with MEA and OASE® blue results from Niederaussem)
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Test conditions:
- Flue gas flow
Rate = 10,500 lb/hr
- Flue gas CO2
Concentration = 11.6%
-Regenerator
Pressure = 2 bar
- Flue gas to absorber
Temperature = 35oC
- CO2 Capture rate = 90%
(target)
Pilot plant performance against targets: Initial accomplishments and plans
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PerformanceAttribute
Current achievement against target
Remarks
1. CO2 capture rate >90% per target Achieved. Optimized for specific energy.
2. CO2 purity 99.9% dry basis per target Achieved. Low O2 impurity level for EOR applications
3. Plant capacity > 1.5 MWe per design target (>15,500 lbs/hr flue gas)
Achieved. Higher capacity testing performed ~10 days in May-June
4. Regenerator steamconsumption
~ 2.8 GJ/tonne CO2 (same as Niederaussem consumption)
Energy optimization planned during current parametric test campaign.
5. Emissions controlvalidation
Validation of dry bed (BASF patented) operation per design
Further emissions control optimization during next campaign
6. Regeneratoroperating pressure
-Currently 2 bar compared with 3 bar target
3 bar tests planned at end of parametric tests
7. Validation of uniquefeatures
(i) high capacity packing, (ii) gravity driven intercooler, (iii) blower downstream of abs.(iv) unique reboiler design.
Optimization of lean-rich heat exchanger for energy reduction during next campaign
Note: Regenerator steam consumption above is intrinsic and does not include process and heat integration
Summary and conclusions
– Linde and BASF are partnering in the development of an advanced PCC technologyincorporating BASF’s novel amine-based process, OASE® blue, along with Linde'sprocess and engineering innovations
– Performance demonstrated and long term stability validated on a 0.45 MWelignite fired power plant flue gases (Niederaussem, Germany)
– Nominal 1 MWe pilot plant at the NCCC in Wilsonville, AL commissioned; initialoperations & testing have demonstrated stable operation, validation of functionalfeatures and initial achievement of several key targets
– Continued parametric testing campaign in progress. Parametric tests aimed atenergy optimization, emissions minimization and validation of higher pressureregenerator operation. This will be followed by long duration testing (4-6months) to demonstrate solvent stability.
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Acknowledgements & Disclaimer
Acknowledgement: This presentation is based on work supported by the Department of Energy under Award Number DE-FE0007453.
DOE-NETL Project Manager: Andrew Jones
NCCC: Justin Anthony (Lead contact)
BASF: Sean Rigby, Gerald Vorberg & Gustavo Lozano
Linde: Torsten Stoffregen, Annett Kutzschbach, Dirk Bauersfeld, Stevan Jovanovic, Devin Bostick, Makini Byron, Luis Villalobos, Drew Amis, Edgar Perez
Disclaimer: “This presentation was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.”
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Thank you for your attention!
Project DE-FE00074532015 NETL CO2 Capture Technology MeetingKrish R. Krishnamurthy, Linde LLCJune 24, 2014Pittsburgh, PA